Replacing the High Pressure Fuel Pump - HPFP

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﻿OVERALL DIFFICULTY INDEX: 6/10

IF YOU HAVE NO TOOLS, YOU PAY $50 TO GET THEM FOR THIS JOB

IF YOU HAVE NO EXPERIENCE YOU SPEND 8 HOURS TO CARRY OUT THIS JOB

SAFETY: RISKS OF BURNS, FUEL SPLASH, SEE BELOW.​

BEFORE YOU START

Always work on cold engines to avoid burns.

This intervention concerns high pressure circuits where fuel pressure can reach 150 bars. That's no joke! A minimum of experience in DIY mechanics is required. The fuel circuit would need to be bled as explained in the pictorial.

Replace this HPFP of a Direct Injection Petrol Engine.

The below works occurred on a Peugeot 5008 equipped with an EP6 direct injection and turbocharged engine. HPFP removal on other engines is pretty similar to this case.

DISCLAIMER:Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own premises for our own use and satisfaction. Readers who envisage to carry out similar works inspired by the below method shall do this at their own risks and liability.

Symptoms & Diagnosis

Symptoms

-Rough idle at cold start i.e. the first one in the morning.-"Check engine" light goes on during this phase.-Difficult driving during warm-up, engine could stall.-Many codes are generated signalling a measured common rail pressure lower than the setting plus misfiring, and rich mixtures.-Engine runs well after being restarted hot like if nothing happened.-Excessive fuel consumption, average increased by 1.5l/100km.

Diagnostics​ON COLD ENGINE-Plug your scanner in, turn on your ignition key without starting the engine.-Go to the page that shows the fuel pressure regulator OCR.-It will be close to 0%, e.g. reads 5% (picture to the left).-Start the engine and observe the OCR. In normal conditions it surges to more than 50% within the second that follows the engine start and drops back to a lower value, 36% as pictured here below (middle).-In case of trouble, the OCR will remain above 50% in a attempt to raise the common rail pressure-Now go to the page showing the measured common rail pressure. It remains low at 4 to 5 bars, i.e. the pressure generated by the fuel pump in your fuel tank (picture to the right). It could fluctuate up to 7 bars and drop back to 4 or 5. The HPFP did not obey the instruction which denotes a failure.ON HOT ENGINE-Plug your scanner and go straight away to the measured common rail pressure.-The pressure builds up to some 50 bars in a matter of 3 to 4 seconds. This normally takes less than a second.

The below works concerned a Peugeot 5008 equipped with a turbo-charged EP6 engine.Same or similar engines can be found on Peugeot 207, 208, 308, 508, 3008, 5008 and Citroen C4, C4 Sedan, DS3, DS4, DS5 also the Mini Cooper S.

Fabricating a cheap fuel bleed tool

Pierce the hose with the screwdriver as shown.Insert the other end into the bottle and attach it with the sock.Place the bottle in a secure manner and insert the hose in the fuel drain valve.Push the valve needle with the screwdriver while holding well the hose.